installation manual series 9500 marine intercom …...the series 9500 marine intercom system is a...

19532P-76 (09-15) 2015 David Clark Company Incorporated

INSTALLATION MANUAL

SERIES 9500

MARINE INTERCOM SYSTEM

19532P-76 (09-15) i

Table of Contents Cautions and Warnings ................................................................................................... 1 Parts/Tools List ............................................................................................................... 2 Customer Supplied Parts/Tools ...................................................................................... 2 System Overview ............................................................................................................ 3 1. Mounting the Master Station ..................................................................................... 5 2. System Cable Wiring ................................................................................................. 9 3. Radios .................................................................................................................... 11 4. Remote PTT (Optional) ........................................................................................... 12 5. Power Cable ........................................................................................................... 13 6. Master Station Internal Connections ....................................................................... 15 7. Connecting Headsets & Belt Stations ...................................................................... 18 8. Operation ................................................................................................................ 19 9. Testing & Troubleshooting ...................................................................................... 21 Appendix A: Master Station Internal Connections ........................................................ A-1 Appendix B: Waterproof Fuse Kit Installation Instructions ............................................ B-1 Appendix C: Insertion Procedures ................................................................................C-1 Appendix D: Master Station Adjustments .....................................................................D-1 Appendix E: Master Station specifications ................................................................... E-1

List of Figures

Figure 1: Typical 4-Person Layout ................................................................................ 4 Figure 2: Mounting the Master Station .......................................................................... 6 Figure 3: C95-XXLN System Cable ............................................................................ 10 Figure 4: Correct use of Cable Labels ........................................................................ 10 Figure 5: C95-20RD Radio Cable ............................................................................... 11 Figure 6: C95-15RS Remote PTT Cable .................................................................... 12 Figure 7: C95-20PW Power Cable .............................................................................. 13 Figure 8: Power Cable ................................................................................................ 14 Figure 9: Master Station Internal Connections ............................................................ 17 Figure 10: Belt Station Connections ............................................................................. 18 Figure 11: Master Station Controls ............................................................................... 19 Figure A1: Master Station Internal Connections ........................................................... A-1 Figure B1: Proper Assembly of Fuse Holder Kit ........................................................... B-1 Figure C1: Insertion Tool ..............................................................................................C-1

List of Tables

Table 1: System Components ..................................................................................... 3 Table 2: Affixing AMP Connectors ............................................................................. 16 Table 3: Belt Station Operation when Connected to 9500 Marine Intercom System ........................................................................................................ 20 Table 4: Stand-alone Belt Station Operation ............................................................. 20 Table 5: Master Station Specifications...................................................................... E-1

List of Templates

Master Station template .................................................................................................. 7

19532P-76 (09-15) of 22 1

Cautions and Warnings

READ AND SAVE THESE INSTRUCTIONS. Follow the instructions in this installation manual. These instructions must be followed to avoid damage to this product and associated equipment. Product operation and reliability depends on proper installation.

DO NOT INSTALL ANY DAVID CLARK COMPANY PRODUCT THAT APPEARS DAMAGED. Upon unpacking your David Clark product, inspect the contents for shipping damage. If damage is apparent, immediately file a claim with the carrier and notify your David Clark product supplier.

ELECTRICAL HAZARD - Disconnect electrical power when making any internal adjustments or repairs. All repairs should be performed by a representative or authorized agent of the David Clark Company.

STATIC HAZARD - Static electricity can damage components. Therefore, be sure to ground yourself before opening or installing components.

19532P-76 (09-15) of 22 2

Parts/Tools List

Included Parts/Tools

� U9500 Master Station (40794G-03) Qty: 1

� U9510BS Belt Station(s) (40795G-03) Customer Specified Qty

� C95-12BS Belt Station Cable (straight) (40798G-01) 1 Req’d for each Belt Station

� C95-15BS Belt Station Cable (coiled) (40872G-01) 1 Req’d for each Belt Station

� C95-XXLN System Cable (40877G-XX) 1 Req’d for each Belt Station

� C95-20RD Radio Cable (40919G-02) 1 Req’d for each Radio

� C95-15RS Remote PTT Cable (40800G-01) Optional

� C95-20PW Power Cable (40919G-01) Qty: 1

� H9530 Over-the-Head Headset (40864G-02) Customer Specified Qty

� H9540 Behind-the-Head Headset (40797G-02) Customer Specified Qty

� C9500PR Portable Radio Cord (40799G-01) 1 Req’d for each Portable Radio

� Master Station Mounting Kit (40688G-62) Qty: 1

� Cable Fittings & Nuts As Required

� Blue 8-pin AMP connectors 1 per Belt Station and Radio

� Yellow 3-pin AMP connector Qty: 1

� White 3-pin AMP connectors 1 per Remote PTT

� AMP tool 59803-1 for blue & white connectors Qty: 1

� AMP tool 59804-1 for yellow connectors Qty: 1

� Labels for Cables (19533P-53) 1 sheet

Customer Supplied Parts/Tools

� Screwdriver Assortment

� Pen/Pencil

� Drill & Bits

� Heat Shrink tubing 1/8” & 3/8 Inch

� Wire Strippers

� Wire Cutters

� Needle-Nose pliers

� Tape Measure

� X-Acto/Razor knife

� Heat gun

� Radio adapters (for interfacing with radios—supplied by radio manufacturer)

� Pin assignments for each radio adapter (supplied by radio manufacturer)

19532P-76 (09-15) of 22 3

System Overview The Series 9500 Marine Intercom System is a weather-tight communication system designed for the marine environment. It allows a captain, co-captain, and two passengers* to communicate with each other over the intercom. All positions also have the ability to communicate through up to three mobile radios. Any one of these radios could be replaced with a Stereo or CD player. Primary components of the system are indicated in Table 1. In addition, a basic layout of a 4-position system is shown in Figure 1.

Component Parts and Model Numbers

Master Station Master Station – Model Number: U9500

Headsets (up to 6)

Over-the-Head Style – Model Number: H9530

Behind-the-Head Style – Model Number: H9540

Cables

In-Line System Cable (1 per headset)

• 10 ft length – Model Number: C95-10LN



Belt Station Cable (1 per Belt Station)

• Straight Cable – Model Number: C95-12BS

• Coiled Cable – Model Number: C95-15BS

Power Cable – Model Number: C95-20PW

Radio Cable – Model Number: C95-20RD

Remote PTT Switch Remote PTT Switch - Model Number C95-15RS

Belt Stations

Belt Station – Model Number: U9510BS

• Belt Station Holster – Model Number: U9510BH

Table 1: System Components

* Up to 8 total positions is possible by modification. Call the David Clark Co, Inc Customer Service Dept. at 800.298.6235 for more information.

19532P-76 (09-15) of 22 4

U9500Master Station

To Power13.8 or 24 V.D.C.

RemotePTT 1

RemotePTT 2

C95-20PW(40919G-01)Power Cable(Ref. Fig.B)

1 Ea. Req D.

C95-XXLN(40877G-XX)System Cable

(Ref. Fig.B)4 ea. Shown

C95-15RS(40800G-01)

Remote SwitchCable

C95-20RD(40919G-02)Radio Cable3 Ea. Shown

C95-12BS(40798G-01) Cable or

C95-15BS(40872G-01) Coil Cord

4 Ea. Shown

U9510BS*(40795G-03)Belt Station

4 Ea. Shown

3/4” Dia.Cable Fitting

3 Req D

40794G-03

BeltStation

Co-Captain

BeltStation

Captain

BeltStation

Crew 1

Radio 1 Radio 2 Radio 3

* Belt Station Holster U9510BH (40796G-01)

BeltStation

H9540 (40797G-02) BTH orH9530 (40864G-02) OTH

Headset4 Shown

Crew 2

Hand HeldRadio

Figure 1: Typical 4-Person Layout

19532P-76 (09-15) of 22 5

1. Mounting the Master Station

Parts/Tools Required

� U9500 Master Station (40794G-03)

� Philips-Head Screwdriver

� Slotted Screwdriver

� 11/32-inch nut driver or wrench

� Tape Measure

� Pencil

� Drill

� 3/16” Drill Bit

� Master Station Mounting Kit (40688G-62)

Procedure

Location Considerations

Choose a location on a vertical wall that will allow access by the operator and also allow the

cover to be removed should adjustments be necessary. The ¾” cable fittings should be facing down toward the deck to reduce the chance moisture entering the enclosure. The Master Station is weather-tight, however the mounting location should chosen to minimize direct water exposure.

Mounting

� Using a Philips screwdriver, remove the 4 screws on the cover of the Master Station and lift off the cover. Observe the 4 mounting holes in each corner, as shown in Figure 2.

� Position the Master Station Drilling Template on the mounting surface and mark each hole with a pencil.

� Confirm the location and carefully drill each hole using the drill and 3/16” bit.

� Position the Master Station on the mounting surface and insert a 3/16” machine screw into each mounting hole.

� On the backside of the mounting wall, use a flat washer, a lock washer, and a nut to secure the Master Station (Figure 2).

19532P-76 (09-15) of 22 6

Figure 2: Mounting the Master Station

19532P-76 (09-15) of 22 7

19532P-76 (09-15) blank of 22 8

19532P-76 (09-15) of 22 9

2. System Cable Wiring


� C95-XXLN System Cable (40877G-XX) One for each Belt Station position to be installed

� System Cable labels

� Tape Measure

Procedure

� Determine the locations of each intercom position. Choose locations based on the customer’s requirements and maneuverability.

� Determine the path of the cable between each position and the Master Station. The cable should be routed using under-deck conduits and be as far as possible from radio antenna coax cables and anywhere water may collect.

� Route the cable. Start at the Belt Station location and feed the end with 2½” of insulation removed toward the Master Station. The end with the large Nexus jack connects to the Belt Station. Use grommets each time the cable is passed through a wall or surface. Use wire ties where necessary.

� Determine the function of the position (Captain, Co-Captain, Crew1, Crew2). Insert the cable into the correct cable fitting on the Master Station. The correct fitting to use is dependant upon the function of the position, see Appendix A.

� Pull cable through fitting approximately 2-3 ft to allow room for termination.

� Using the provided cable labels, label the cable once it is through the fitting and inside the Master Station (Figure 4).

� Repeat this procedure for each Belt Station position you are installing.

� Termination of this end of the cable is performed in Section 6.

19532P-76 (09-15) of 22 10

1

2

34

5

6

7

EXTERNAL

PIN VIEW

NEXUS AJ-107BR

1

6

2

5

8

3

7

2

5

1

4

3

7

6

RED RED

WHT WHT

GRN GRN

BLK BLK

BRN BRN

ORG ORG

BLUE SHIELD

MIC HI

+ 8V

EAR HI

GND

REMOTE PTT

PTT HI

SHIELD

MIC HI

+ 8V

EAR HI

GND

REMOTE PTT

PTT HI

SHIELD

To Master Station Main P.C. BoardJ1, J2, J3, and J4

D.C.C.I. Cable09271P-35 HA000

or equivalent

Measure and StripJacket 2-1/2” from

Cable End

C95-XXLNSystem Cable

P/N 40877G-XX

Figure 3

Figure 4: Correct use of cable labels

19532P-76 (09-15) of 22 11

3. Radios Parts/Tools Required

� C95-20RD Radio Cable (40919G-02) One for each radio in the system, max of 3.

� Radio adapters (for interfacing with radios; supplied by radio manufacturer)

� Pin assignments for each radio adapter (supplied by radio manufacturer)

� Tape Measure

� Wire Cutters

� Wire Strippers

� Soldering Iron/Solder

� Heat Shrink Tubing 1/8”

� Heat Gun

� Radio Cable labels

1

2

3

4

5

6

MIC HI

MIC LO

PTT HI

PTT LO

EAR HI

EAR LO

RADIO MIC HI

RADIO MIC LO

RADIO P.T.T HI

RADIO P.T.T LO

RADIO SPKR HI

RADIO SPKR LO

RADIO P.T.T LO

To Radio1 (J1)

Radio2 (J4)

Radio3 (J5)

RED

WHT

ORG

BRN

GRN

BLK

TO RADIO

D.C.C.I Cable09271P-35HA000

or Equivalent

See Note 1 See Note 3

Measure and StripJacket 4” from

Cable End

See Note 2, 3

C95-20RDRadio Cable

P/N 40919G-02

To Master StationCover P.C. BoardJ1, J4, and J5

Procedure Figure 5

� Determine the locations of each radio. The radios should already be installed and tested.

� Determine the path of the cable between each radio and the Master Station. The cable should be routed using under-deck conduits and be as far as possible from radio antenna coax cables and anywhere water may collect.

� Measure the length of cable necessary, adding 3 ft as a service loop.

� If necessary, trim the length of the cable to the length you just determined in the previous step.

Be sure to trim the un-prepared Radio end of the cable. See Figure 5 above.

� Route the cable. Use grommets each time the cable is passed through a wall or surface. Use wire ties where necessary.

� Determine which number radio this cable corresponds to (Radio 1, Radio 2 or Radio 3)

� Feed the Master Station end of the cable through the correct cable fitting. The correct fitting to

use is dependant upon which number radio this cable goes to. See Appendix A.


� Using the provided cable labels, label the cable once it is through the fitting and inside the Master Station (Figure 4).

� Review pin assignments for radio connector and determine which wires to connect to each pin.

Using wire cutters and wire strippers, prepare the cable for the connector. Install the connector, using heat shrink tubing as necessary. The shield in this cable should be connected to GND or PTT LO on the radio, along with the Brown wire. See Figure 5 & Appendix A.

� Repeat this procedure for each radio in the system.

19532P-76 (09-15) of 22 12

4. Remote PTT (Optional)

Parts/Tools Required � C95-15RS Remote PTT Cable (40800G-01) Maximum of 2

� Tape Measure

� Wire Cutters

� Wire Strippers

� Remote PTT Cable Labels

1

2


Cable End

P.T.T

WHITE

BLACK

C95-15RSRemote PTT Cable

P/N 40800G-01

To Master StationMain P.C. Board J6 & J7

Figure 6

Procedure

� Determine the locations of each PTT switch. Choose location based on customer requirement and accessibility (typically on the throttle).

� Determine the path of the cable between each PTT switch location and the Master Station. The cable should be routed using under-deck conduits and be as far as possible from radio antenna coax cables and anywhere water may collect.

� Estimate the length of the cable necessary, adding 3 ft as a service loop.

� If necessary, trim the length of the cable to the length you just estimated. Be sure to trim the end of the cable that does NOT have the PTT switch.


� Determine which Remote PTT switch this cable corresponds to (Captain or Co-Captain).

� Feed the Master Station end of the cable through the F1 fitting on the Master Station. See Appendix A.


� Using the provided cable labels, label the cable once it is through the fitting and inside the Master Station.

� Repeat this process for the 2nd

Remote PTT switch (if applicable).

19532P-76 (09-15) of 22 13

5. Power Cable


� C95-20PW Power Cable (40919G-01)

� 2-Amp Circuit Breaker location on ship or David Clark 2-Amp Fuse kit (40688G-47)

� Soldering iron or crimp terminals

� Wire cutters

� Tape Measure

� Wire strippers

� Power Cable label

1

2

+13.8 V.D.C

GND

D.C.C.I. Cable09815P-20 HA000

or Equivalent

Switched +13.8 V.D.C

+13.8 V.D.C Return


Cable End

RED

BLK

C95-20PWPower Cable

P/N 40919G-01

To Master StationMain P.C. Board J5

Figure 7

Procedure

� Determine the location of the 11-30VDC source and Ground pick-off points o Preferably a 2-Amp circuit breaker o Connection method (solder, screw terminals, lugs, etc)

� If only a higher-amperage circuit breaker is available, it may be used, but the David Clark 2-Amp Fuse Kit (40688G-47) must also be used.

� Determine the path of the cable between the power source and the Master Station. The cable should be routed using under-deck conduits and be as far as possible from radio antenna coax cables and anywhere water may collect.

� Measure the length of cable necessary, adding 3 ft as a service loop.

� If necessary, trim the length of the cable to the length you just determined in the previous step.


� Feed the Master Station end of the cable through the F1 cable fitting. See Appendix A.


� Using the provided cable labels, label the cable once it is through the fitting and inside the Master Station.

19532P-76 (09-15) of 22 14

Before continuing, ensure that power is shut off to the point where you are going to connect the power cable

� Using the wire cutters and wire strippers, prepare the power source end of the cable as shown in

Figure 8 below. � If using the David Clark 2-Amp Fuse Kit, please see Appendix B for assembly instructions. � Connect the cable to the power source

o Connect the RED to the positive (+) terminal.

o Connect the BLACK and SHIELD to the negative (-) terminal

� Do not turn on power at this time, wait until Section 9: Testing & Troubleshooting.

To 2 ampcircuitbreaker/fuse

RED

BLACK/SHIELD

Figure 8: Power Cable

19532P-76 (09-15) of 22 15

6. Master Station Internal Connections


� Blue AMP connectors (One for each Radio cable and each System cable)

� Yellow AMP connector (One required for Power cable)

� White AMP connectors (One for each Remote PTT cable)

� AMP tool 59803-1 for blue & white connectors

� AMP tool 59804-1 for yellow connectors

� Screwdriver (for top cover screws)

� Waterproof sealant/caulking

Procedure Affixing AMP Connectors to Cables

� Using the chart in Table 2 (next page), affix the correct connector to each cable.

o Use the Correct AMP Tool for each connector. o See Appendix C for proper wiring and use of AMP tools.

� Place the connector on a flat surface or suitable support to prevent rocking when inserting the wires.

� Position wire over the contact in the AMP connector. Make sure the end of the wire does not extend over the shoulder of the connector. Start the wire into contact with finger.

� Place appropriate tool on wire over contact so that the center line of the tool matches the contact. The tool must be positioned as shown in Appendix C.

� Holding the tool handle perpendicular to the contact, apply a constant, direct pressure until the wire is terminated with the contact. Exert pressure in such a manner as to avoid contact damage.

� Ensure that a good connection is made to each terminal on the connectors. The wires should look just like the picture. Trim cable and reinstall any connectors that are not done properly.

19532P-76 (09-15) of 22 16

Cable Type

Connector(s) on Master

Station

Connector Type

Correct AMP Tool

Connector Wiring Diagram

System Cables

Main Board: J1-J2-J3-J4

Blue Connector

59803-1

09271P-35HA000SYSTEM CABLECONDUCTORS

BLUE HEADER

Radio Cables

Cover Board: J1-J4-J5

Blue Connector

59803-1

09271P-35HA000RADIO CABLECONDUCTORS

BLUE HEADER

PTT Cables

Main Board: J6-J7

Small White Connector

59803-1

SMALL WHITE HEADER

REMOTE PTT CABLE CONDUCTORS

Power Cable

Main Board: J5

Large Yellow Connector

59804-1

09815P-20HA000POWER CABLECONDUCTORS

LARGE YELLOW HEADER

Table 2: Affixing Amp Connectors

19532P-76 (09-15) of 22 17

Attaching AMP Connectors to Master Station

� Using Figure 8, Plug each AMP connector onto the proper mating pins on the board.

� Double-check that the pins on each connector are aligned correctly and that each connector is plugged into the correct set of pins.

� Pull any slack in each cable through the cable fittings. Tighten cable fittings snugly, but by hand.

� Use a waterproof sealant or caulking to fill any unused holes in the fittings.

� To ensure proper fitting of top cover, route cables as shown in Figure 8.

� Carefully place cover on the Master Station, watching for any wires that might be in the way or stick out the sides.

� Use the 4 screws to securely tighten the cover.

RADIO CABLESIGNALS FORJ1, J4, AND J5

1-MIC HI (RED)2-MIC LO (WHITE)3-PTT HI (ORANGE)4-PTT LO (BROWN)5-EAR HI (GREEN)6-EAR LO (BLACK)7-N.C.8-N.C.

SYSTEM CABLESIGNALS FOR

J1 AND J2

1-MIC HI (RED)2-EAR HI (GREEN)3-PTT HI (ORANGE)4-MIC HI (RED) FOR PARALLED STATION5-GND (BLACK)6-+8V (WHITE)7-SHIELD (JUMPER BLUE)8-REMOTE PTT (BROWN)


J3 AND J4

1-MIC HI (RED)2-EAR HI (GREEN)3-PTT HI (ORANGE)4-MIC HI (RED) FOR PARALLED STATION5-GND (BLACK)6-+8V (WHITE)7-SHIELD (JUMPER BLUE)8-NO REMOTE PTT

8 7 6 5 4 3 2 1

J1

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

9 8 7 6 5 4 3 2 110111213141516

9 8 7 6 5 4 3 2 110111213141516

1 2 3

J8

J7J6

J5 J1 J2 J3 J4

Radio 1

Radio 2

Radio 3

RX1 Level

R3

TX1Level

8 7 6 5 4 3 2 1

J5

8 7 6 5 4 3 2 1

J4

RX3 Level

R21R2

RX2 Level

R10

Rev. B

Rev. B

R17

TX2Level

TX3Level

3 2 13 2 1R30R77

ListenLevelAdjust

Power

Captain Co-Captain (Crew 1) (Crew 2)

Remote PTT 1Captain

Remote PTT 2Co-Captain

J9

POWER (J5)

1 - RED2 - BLACK3 - N.C.

U9500 MASTER STATION COVER

Figure 9: Master Station Internal Connections

19532P-76 (09-15) of 22 18

7. Connecting Headsets & Belt Stations


� C95-10BS Belt Station(s)

� C95-12/15BS Belt Station Cable(s) (straight or coiled)

� H9530/H9540 Headset(s)

� Hand-held radio (optional)

� Cord for hand-held radio (optional)

Procedure

� Examine Figure 10 which shows the interconnections on the Belt Station.

� Connect the black/green connector on the headset cable to the black/green jack on the Belt Station by aligning the colored lines and pushing together until they lock. To remove, turn collar counter-clockwise and pull.

� Connect the black/red connector on the Belt Station Cable to the black/red jack on the Belt Station by aligning the colored lines and pushing together until they lock. To remove, turn collar counter-clockwise and pull.

� Connect the system end of the Belt Station Cable (large black/green plug) to the mating jack on the System Cable by aligning the keyway and pushing until it locks into place. To remove, simply pull apart.

� If you are also connecting a hand-held radio, connect the yellow/black end of the hand-held radio cable to the yellow/black jack on the Belt Station. The other end connects to the radio. Always be sure the hand-held radio is off while connecting or disconnecting from the Belt Station.

� Repeat the procedure for each Belt Station location in the system.

I n t e r c o m - R a d i o S e l e c t

S w i t c h

H e a d s e t C o n n e c t o r C o l o r C o d e d

“ G r e e n ”

P u s h - T o - T a l k

( P . T . T ) S w i t c h

B E L T S T A T I O N

4 0 7 9 5 G - 0 3

W O R C E S T E R , M A

U S A

0 1 6 1 5 - 0 0 5 4

I n d i v i d u a l V o l u m e

C o n t r o l

I n t e r c o m C o n n e c t o r C o l o r C o d e d

“ R e d ”

H a n d - H e l d

R a d i o C o n n e c t o r C o l o r C o d e d

“ Y e l l o w ”

R

Figure 10: Belt Station Connections

19532P-76 (09-15) of 22 19

8. Operation

Operation of Master Station The Master Station controls radio access and volume levels for the 9500 Marine Intercom System.

1. Radio Rx Volume adjusts the receive audio level of all three radios on the intercom. 2. System Volume adjusts the voice level of all of the users on the intercom. 3. The toggle switches control whether the Rx audio from the radios can be heard. Each radio has

its own Rx Audio On/Off switch. 4. The Radio Select switch determines which radio is active for transmitting.

ON

RX 3

RADIO RXVOLUME

RADIO SELECT1 2 3

SYSTEMVOLUME

ON

RX 2

R R

Figure 11: Master Station Controls

19532P-76 (09-15) of 22 20

Operation of Belt Station The Belt Station is a dual-purpose interface allowing for intercom or stand-alone use. When the Belt Station is connected to the 9500 Intercom System, it’s user can access the boat’s radios and speak with other users on the intercom. When disconnected from the intercom, operation defaults to the user’s handheld radio (if present). See Tables 3&4 for details of operation.

Belt Station Connected to Intercom, with or without Hand-Held Attached

Intercom/Radio Switch

Position

Connected to Intercom?

PTT function Headset Can Hear:

IC YES PTT enables user to speak over intercom; No ship radio transmit

Intercom, Ship radio, Hand-held radio (if

connected)

RAD YES User has “hot mic” over intercom; PTT enables transmit over ship

radio

Intercom, Ship radio, Hand-held radio (if

connected)

Table 3: Belt Station Operation when connected to 9500 Marine Intercom System

Belt Station with Hand-Held Radio Attached and NOT Connected to Intercom

Intercom/Radio Switch

Position

Connected to Intercom?

PTT function Headset Can

Hear:

IC NO PTT enables transmit over hand-held

radio Hand-held radio

RAD NO PTT enables transmit over hand-held

radio; VOX also enabled (if supported by radio)

Hand-held radio

Table 4: Stand-alone Belt Station operation

19532P-76 (09-15) of 22 21

9. Testing & Troubleshooting


� Completion of the previous sections in their entirety

� An assistant (optional)

Test Procedure

� Double-Check all connections and wiring from the previous sections.

� Complete connections of power cables to power source.

� Turn on power at the source.

� From each Belt Station verify intercom communication.

o With IC/RAD switch in RAD mode the user has “hot-mic” over intercom. o With IC/RAD switch in IC mode the user must press the PTT to talk over the intercom.

� From each Belt Station verify receive and transmit capability over each radio in the system.

o Flip switches for each radio on the Master Station to the ON position (up). � Verify receive audio from each radio.

o IC/RAD switch must be in RAD mode, only then does PTT key the radio. o At the Master Station, switch to each radio with the selector switch and verify PTT/Mic.

� This switch controls which radio the Belt Stations have Mic/PTT access to. o Open the squelch on each radio and verify that it is heard in each headset.

� Test portable radio access from each Belt Station o Connect portable radio to Belt Station. o With Belt Station also connected to main system, the user should only have Rx access to

hand-held radio. o Remove Red connector (intercom) from the Belt Station. o Confirm Tx & Rx to hand-held radio.

19532P-76 (09-15) of 22 22

Troubleshooting

Symptom Possible Cause(s)

Cannot hear any audio in headset(s)

1. Power to system turned on? 2. System Volume setting up to an audible level? 3. Radio Volume settings up to an audible level?

Cannot speak over intercom

1. Power to system turned on? 2. Belt Station IC/RAD switch in IC mode? If so, need to PTT for intercom

No (or low) radio receive audio

1. Power to system turned on? 2. Radio turned on? 3. Radio’s volume setting up to an audible level (on radio)? 4. Check radio settings/wiring.

No boat radio transmit

1. Power to system turned on? 2. Radio turned on? 3. Belt Station IC/RAD switch in IC mode? Must be in RAD mode. 4. Check radio settings/wiring.

No handheld radio transmit

1. Power-off and then power-on the handheld radio

Too low or too high radio transmit audio

2. See Appendix D for adjustment information.

Belt Station not receiving/transmitting

1. Check above suggestions 2. Check Belt Station wiring

Other audio level problems

1. See Appendix D for adjustment information.

19532P-76 (09-15) A-1

Appendix A Master Station Internal Connections

RADIO CABLESIGNALS FORJ1, J4, AND J5

1-MIC HI (RED)2-MIC LO (WHITE)3-PTT HI (ORANGE)4-PTT LO (BROWN)5-EAR HI (GREEN)6-EAR LO (BLACK)7-N.C.8-N.C.


J1 AND J2

1-MIC HI (RED)2-EAR HI (GREEN)3-PTT HI (ORANGE)4-MIC HI (RED) FOR PARALLED STATION5-GND (BLACK)6-+8V (WHITE)7-SHIELD (JUMPER BLUE)8-REMOTE PTT (BROWN)


J3 AND J4

1-MIC HI (RED)2-EAR HI (GREEN)3-PTT HI (ORANGE)4-MIC HI (RED) FOR PARALLED STATION5-GND (BLACK)6-+8V (WHITE)7-SHIELD (JUMPER BLUE)8-NO REMOTE PTT

8 7 6 5 4 3 2 1

J1

1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8

9 8 7 6 5 4 3 2 110111213141516

9 8 7 6 5 4 3 2 110111213141516

1 2 3

J8

J7J6

J5 J1 J2 J3 J4

Radio 1

Radio 2

Radio 3

RX1 Level

R3

TX1Level

8 7 6 5 4 3 2 1

J5

8 7 6 5 4 3 2 1

J4

RX3 Level

R21R2

RX2 Level

R10

Rev. B

Rev. B

R17

TX2Level

TX3Level

3 2 13 2 1R30R77

ListenLevelAdjust

Power

Captain Co-Captain (Crew 1) (Crew 2)

Remote PTT 1Captain

Remote PTT 2Co-Captain

J9

POWER (J5)

1 - RED2 - BLACK3 - N.C.

U9500 MASTER STATION COVER

Figure A1: Master Station Internal Connections

19532P-76 (09-15) B-1

Appendix B

P/N 40688G-47 Waterproof Fuse Kit Installation Instructions


• 1/8-inch diameter heat shrink tubing

• Wire strippers • Crimp tool (Radio Shack P/N 64-409 or equivalent) • Crimp terminals

• 2-Amp fuse kit

Procedure

1. Using a heat gun, install 1/8" diameter heat shrink tubing* over one end of the 4" red wire (supplied). Install the second piece of 1/8" diameter heat shrink tubing over the red wire on the C98-20PW Power Cable.

2. Thread red wire of power cord with heat shrink tubing* into one end of fuse holder. 3. Thread the heat shrink end of the 4-inch red wire into other end of fuse holder. 4. Strip insulation on both wires 1/4 inch. 5. Crimp fuse clips to both wires. (Recommended crimp tool Radio Shack No. 64-409 or

equivalent). 6. Insert 2 amp fuse. 7. Snap two halves of housing together.

Figure B1: Proper assembly of Fuse Holder Kit (40688G-47)

* Note: The heat shrink tubing is necessary in order to provide weather tightness.

19532P-76 (09-15) C-1

Appendix C

AMP INSERTION TOOLS 59803-1 AND 59804-1

The tool number is stamped on the tool side and the Amp marking is molded on both sides. Insertion tool 59803-1 is designed for connectors with contacts on .100-in. centers (MTA 100), and insertion tool 59804-1 is designed for connectors with .156-in. centers (MTA 156).

INSERTION PROCEDURES

1. Place the connector block on a flat surface or suitable support to prevent possible rocking

when inserting the wire. 2. Position wire over the contact in the MTA connector. Make sure the end of the wire does

not extend over the shoulder of the connector. Start the wire into contact with finger. 3. Place appropriate tool on wire over contact so that the centerline of the tool matches the

contact. The tool must be positioned as shown in Figure below. 4. Holding the tool handle perpendicular to the contact, apply a constant, direct pressure until

the wire is terminated with the contact. Exert pressure in such a manner as to avoid contact damage.

5. Remove tool and inspect contact for proper wire insertion. If necessary, repeat the operation.

Figure C1: Insertion Tool

19532P-76 (09-15) D-1

Appendix D Master Station Adjustments

Radio Transmit Level Adjustments

These adjustments have been pre-set to optimum levels and should not need to be performed in the field. However, they are included in this section should their adjustment be necessary. To increase or decrease the transmit mic audio level for Radio 1, locate and adjust R3 on the inside of the U9500 Master Station. For Radio 2, locate and adjust R17. For Radio 3, locate and adjust R30. (see Figure A1 for the locations of these components). Turning the potentiometers clockwise will increase the levels and counter-clockwise will decrease the levels. Use a jeweler’s screwdriver to make these adjustments. Please note that these are multi-turn potentiometers, so several rotations may be necessary to achieve the desired results.

It is also important not to increase the levels so much as to over-modulate the radios. This is in violation of FCC regulations and will seriously degrade the quality of the transmissions. If you have the equipment to measure the modulation, 4-4.5 KHz is an optimum deviation level.

Radio Receive Level Adjustments The factory has pre-set the receive audio adjustment potentiometers to levels which should be acceptable in most applications. Should the need arise to change these settings, the installer may do so by the following procedure:

To increase or decrease the receive audio levels for Radio 1, locate and adjust R2 inside the U9500 Master Station. For Radio 2, locate and adjust R10. For Radio 2, locate and adjust R21 (see Figure A1 for the locations of these components). Please note that these are multi-turn potentiometers, so several rotations may be necessary to achieve the desired results.

System Volume Level Adjustment

The system volume (intercom volume) level is adjusted from the U9500 Master Station’s System Volume knob. These instructions are provided should additional adjustment be necessary. To increase or decrease the system volume level, locate and adjust R77 (See Figure A1). Please note that this is a multi-turn potentiometer, so several rotations may be necessary to achieve the desired result.

19532P-76 (09-15) E-1

Appendix E

Master Station Specifications

Enclosure: Weather-tight RFI shielded enclosure for increased reliability Cast Aluminum "Aluform" NEMA enclosure black

Operating Temperature:

-40C to +60C

Frequency Response:

300 Hz to 3 kHz

Output Levels: System output adjustable to headset ears: 0.25VRMS to 3.0 VRMS

with normal speech levels.

Radio TX Audio:

System provides transformer-coupled Radio TX Audio output (600 ohms secondary) with a level adjustment. Radio 1 and 2 each have a maximum output level of 870 mVRMS.The maximum output level of Radio 3 is 1.7 VRMS. TX Audio outputs for all three radios are based on a 98 dB SPL 1/4" from the headset microphone.

Radio RX Audio: System has transformer-coupled audio input (600 ohms primary) and can be adjusted for various input levels (depending on Radio Volume Setting).

Radio Inputs: Provides connection for up to three mobile radios.

Radio Connection:

MTA-100 Amp Closed End Housing with pins spaced on 0.100" centers. Header is mounted onto PC board and cable is secured with a waterproof cable fitting on the Master Station housing.

Crew Members: Up to 8 headsets (pairs wired in parallel)

Power Requirements:

13.8 or 24 Volts DC (Maximum Current 1A)

Dimension: 7.87" L x 3.94" W x 2.36" H

Weight: 2.48 lbs.

Table 5: Master Station Specification

installation manual series 9500 marine intercom …...the series 9500 marine intercom system is a...

Documents